Auxiliary Lights '07 FJ Cruiser IssC

TOYOTA FJ CRUISER 2007 AUXILIARY LIGHTS Preparation NOTE: Part number of this accessory may not be the same as the part number shown. Part Number: PT297-35061 Kit Contents Item # 1 2 3 4 Quantity Reqd. 2 1 1 2 Description Driving Lamp Assembly Switch Harness Lamp Harness Stone Shield General Applicability All Models Hardware Bag Contents Item # 1 2 3 4 5 6 7 8 Quantity Reqd. 1 1 1 16 1 2 1 1 Recommended Sequence of Application Description Relay 15A Fuse Switch 7” Tie Wrap 24” Tie Wrap T-Tap Connectors Foam Tape Car Care Guide Item # 1 2 3 *Mandatory Vehicle Service Parts (may be required for reassembly) Additional Items Required For Installation Item # 1 Quantity Reqd. 1 Description FJ Auxiliary Lamp Bumper Brackets (PT297-35062) if vehicle does not have brush guard 2 Conflicts None Recommended Tools Personal & Vehicle Protection Notes Safety Goggles Watch and Belt Buckle Protectors, Blankets Protective Tape Special Tools Notes Torque wrench Shop Vacuum Drill Template 10-50 lbs-ft. IADS: FJC07-044-01 Installation Tools Notes Accessory Off Road Lights Auxiliary Lights TVIP Item # 1 2 3 Quantity Reqd. Description Legend STOP: Damage to the vehicle may occur. Do not proceed until process has been complied with. OPERATOR SAFETY: Use caution to avoid risk of injury. CAUTION: A process that must be carefully observed in order to reduce the risk of damage to the accessory/vehicle and to ensure a quality installation. TOOLS & EQUIPMENT: Used in Figures calls out the specific tools and equipment recommended for this process. 12mm Socket/box wrench 17mm Socket/box wrench 10mm Socket Panel Removal Tool Drill 7/8” Hole Saw Side Cutters Long Nose Pliers Exacto Knife Masking Tape Special Chemicals Issue: C 06/03/08 Notes Page 1 of 15 pages DIO

TOYOTA FJ CRUISER 2007 - AUXILIARY LIGHTS Procedure Care must be taken when installing this accessory to ensure damage does not occur to the vehicle. The installation of this accessory should follow approved guidelines to ensure a quality installation. These guidelines can be found in the "Accessory Installation Practices" document. This document covers such items as: Vehicle Protection (use of covers and blankets, cleaning chemicals, etc.). Safety (eye protection, rechecking torque procedure, etc.). Vehicle Disassembly/Reassembly (panel removal, part storage, etc.). Electrical Component Disassembly/Reassembly (battery disconnection, connector removal, etc.). Please see your Toyota dealer for a copy of this document. 1. Vehicle Dissemble 10 mm Socket (a) Set parking brake. (b) Remove the negative battery cable (Fig. 1-1). (1) Protect the fender before starting. (2) Do not touch the positive terminal with any tool when removing cable. (c) Wait 90 seconds before proceeding to disassemble vehicle. Fig. 1-1 NOTE: Place all removed parts on a protected surface. NOTE: When disconnecting wiring connectors do not pull on the wiring, pull on the connector only. (d) Add protective tape to front bumper and grill (Fig. 1-2) Fig. 1-2 Panel Removal Tool and 10 mm Socket (e) Remove Front Grill (1) Remove two clips and two screws. (Fig. 1-3) Pull (2) Disengage the five clips and remove the radiator grill by pulling straight forward. Fig. 1-3 Issue: C 06/03/08 Page 2 of 15 pages DIO

TOYOTA FJ CRUISER 2007 - AUXILIARY LIGHTS Procedure Panel Removal Tool (3) Remove the two clips. (Fig. 1-4) Fig. 1-4 Panel Removal Tool (f) Remove Lower Instrument Panel Finish (1) Disengage the four clips and two claws and remove the IP register by pulling straight rearward. (Fig 1-5) Fig. 1-5 (2) Disengage the three claws and separate the hood release lever. (Fig. 1-6) Fig. 1-6 (3) Open driver side rear (2nd ) door. Nylon Panel Removal Tool (4) Remove the driver side step cover. (Fig. 1-7) (i) Cover the floor and seats before starting. Step Cover Fig. 1-7 Issue: C 06/03/08 Page 3 of 15 pages DIO

TOYOTA FJ CRUISER 2007 - AUXILIARY LIGHTS Procedure (5) Remove the footrest. (Fig. 1-8) Nylon Panel Removal Tool Footrest Cowl Cover (6) Remove the one nut securing cowl cover and remove cowl cover. (Fig. 1-8) Fig. 1-8 (7) Remove the two screws. (Fig. 1-9) (8) Disengage the five clips and claw and remove the lower IP trim. Fig. 1-9 10 mm Socket (9) Remove the four screws and remove the lower metal instrument panel. (Fig. 1-10) Fig. 1-10 Panel Removal Tool 10 mm Socket (10) Remove the parking brake cover plate. (Fig. 1-11). Fig. 1-11 Issue: C 06/03/08 Page 4 of 15 pages DIO

TOYOTA FJ CRUISER 2007 - AUXILIARY LIGHTS Procedure (11) Shift the lever into the N position. (Fig. 1-12) (i) Remove the shift lever knob(s). Fig. 1-12 (12) Remove the box bottom mat. (Fig. 1-13) Fig. 1-13 (13) Disengage and remove the top panel of center console. (Fig. 1-14) (14) Reattach shift lever knob(s). (15) Remove the four screws. (Fig. 1-15) (16) Carefully disengage the console assembly and position rearward. (17) Cover front portion of console with cloth. Panel Removal Tool Fig. 1-14 10 mm socket Fig. 1-15 Issue: C 06/03/08 Page 5 of 15 pages DIO

TOYOTA FJ CRUISER 2007 - AUXILIARY LIGHTS Procedure (18) Panel Removal Tool and 10 mm Socket Remove the lower instrument console assembly. (Fig. 1-16) (i) Remove the two clips and two screws. (ii) Disengage the three clips and two claws and tilt the instrument console rearward to allow access to remove knockouts. Fig. 1-16 2. Interior Installation of Switch/Wire Harness Auxiliary Switch Location (a) Locate the bottom left unused knockout. (Fig. 2-1) RR DIFF LOCK 400W AC 115V P 100W Fig. 2-1 (b) Install the switch in the orientation shown. (Fig. 2-2) (c) Plug the Auxiliary wire harness 6 pin connector into the Auxiliary switch. Fig. 2-2 (d) Locate the grey connector at the rear of the “RR DIFF LOCK” switch. (Fig. 2-3) RR DIFF LOCK 400W AC 115V P 100W Fig. 2-3 Issue: C 06/03/08 Page 6 of 15 pages DIO

TOYOTA FJ CRUISER 2007 - AUXILIARY LIGHTS Procedure (e) Locate the Green and White-Green wires at the rear of the knockout/switch in location 2. (Fig. 2-4) G & W-G (1) Apply T-taps to the Green wire and White-Green wires. Fig. 2-4 Long Nose Pliers W/H clamp (2) Connect the T-taps from the switch wire harness to the T-taps on the Green and White-Green wires. (f) Route the wire harness from instrument console area and along the vehicle wire harness. (Fig. 2-5) (1) Be sure to route wire harness through the w/h clamp. Fig. 2-5 (g) Continue routing the wire harness down and along vehicle wire harness. (Fig. 2-6) Fig. 2-6 Connector (h) Connect the 13 pin connector of the wire harness to the vehicle connector located in the left side cowl area. (Fig. 2-7) Fig. 2-7 Issue: C 06/03/08 Page 7 of 15 pages DIO

TOYOTA FJ CRUISER 2007 - AUXILIARY LIGHTS Procedure Ground screw (i) Remove the ground screw and attach the ground wire with terminal to the ground point. (Fig. 2-8) 10 mm socket Fig. 2-8 4 Wire ties Foam tape (j) Adjust wire harness so that the slack is located behind the lower instrument panel. (1) Secure the wire harness with four wire ties to the vehicle wire harness. (Fig. 2-9) (2) Secure the wire harness to the air duct with foam tape. Fig. 2-9 (k) Secure wire harness with wire tie to main vehicle wire harness. (Fig 2-10) (l) Cut all excess wire ties. (m) Reposition the lower instrument panel. 2 Wire Ties 3. Exterior Installation of the Lamp wire harness and Auxiliary lights. Fig. 2-10 Wire Tie Two pin connector (a) Locate the two pin connector on the vehicle wire harness. (Fig. 3-1) (1) Remove the break-away tape and connector plug. (2) Plug the accessory wire harness into the two pin connector. (3) Secure the connector to the vehicle harness with wire tie. Fig. 3-1 Issue: C 06/03/08 Page 8 of 15 pages DIO

TOYOTA FJ CRUISER 2007 - AUXILIARY LIGHTS Procedure 24” Wire Tie (b) Route the wire harness along side of the fuse box and battery. (Fig. 3-2) (1) Loosen the battery hold down and slide the battery towards the engine to ease the installation of the wire tie. (2) Secure wire harness with the 24” wire tie to the vehicle wire harness at the location between the fuse box and battery. (Fig. 3-2) Fig. 3-2 3 Wire Ties (c) Secure the wire harness to the vehicle harness behind the headlamp with 3 wire ties and continue the routing of the harness along the vehicle harness. (Fig. 3-3) Fig. 3-3 (d) Continue routing the harness along the vehicle harness in front of the radiator. Secure the wire harness to the vehicle wire harness under the top front radiator support with 4 wire ties. (Fig 3-4) 4 Wire ties Fig. 3-4 4. Installation of Lights on Brush Guard (see step 5 for bumper installation) Nut Center of vehicle (a) Attached the lamps to the Brush Guard. (Fig. 4-1) (1) Confirm that the 14 mm nut is installed towards center of vehicle. Fig. 4-1 Issue: C 06/03/08 Page 9 of 15 pages (i) If necessary remove nut and bolt and reinstall so nut is towards center of vehicle. DIO

TOYOTA FJ CRUISER 2007 - AUXILIARY LIGHTS Procedure (2) Align the lamps so that the brackets are parallel to each other as shown. (3) Tighten each 14 mm nut to 40 lbs-ft. (b) Reattach the front grill with screws and clips. (c) Install the Brush Guard as indicated in the Brush Guard installation instructions. (d) Route the pig tail wire harness from each lamp directly rearward and through the grill. (Fig. 4-2) Fig. 4-2 2 Wire ties (e) Connect the pig tail connectors to the mating connectors on the wire harness. (f) Secure the pigtails connections with 2 wire ties. (Fig. 4-3) Fig. 4-3 Issue: C 06/03/08 Page 10 of 15 pages DIO

TOYOTA FJ CRUISER 2007 - AUXILIARY LIGHTS Procedure Align template along bumper ridge 5. Installation of Lights on Bumper Tape Fig. 5-1 Tape Cardboard (a) Lay left side template on top of bumper and align along ridge with tab against side ridge. (Fig. 5-1) (1) Apply masking tape to template to secure. Align tab along side ridge (b) Center punch the cross hairs. Support bracket (c) Place cardboard between bumper fascia and support bracket to protect metal. (Fig. 5-2) (d) Adjust pilot drill so tip does not exceed height of hole saw teeth. Fig. 5-2 7/8” hole saw, drill (e) At center punch marks, drill 7/8” holes with hole saw. (Fig. 5-2) (1) Be sure not to cut through cardboard and scratch the bumper bracket. Support Tube (f) Repeat steps a though f for right side of bumper. (g) Remove templates and tape. (h) Remove excess rubber material with Exacto knife to expose the four factory provided holes in the bumper support bracket. (i) Vacuum up any remaining rubber material. Fig. 5-3 Torque wrench 12 mm socket (j) Insert bumper support tube into opening beneath the bumper. (Fig. 5-3) Fig. 5-4 Issue: C 06/03/08 (k) Install bumper support tube in the bumper support channel and loosely secure with the 2 M8 bolts and 2 M8 nuts to the center radiator support. (Fig. 5-4) Page 11 of 15 pages DIO

TOYOTA FJ CRUISER 2007 - AUXILIARY LIGHTS Procedure (l) Hand tighten 2 bolts and washers to the outside holes on the top of the bumper. (Fig. 5-5) (m) Tighten the 2 M8 bolts and 2 M8 nuts that attach the support bracket to the center radiator support to 15 lbs-ft. (Fig 5-4) Fig. 5-5 12 mm wrench (n) Reattach the front grill with screws and clips. (o) Remove the 2 bolts and washers holding the support bracket to the bumper. (p) Install left hand lamp bracket with 2 M8 bolts and 2 washers. Tighten the bolts to 15 lbs-ft. (Fig. 5-6) Fig. 5-6 Torque wrench 15 mm socket (q) Repeat for right hand lamp bracket. (r) Remove M10 nut from lamp assembly and attach the lamps to the left and right hand lamp brackets. Tighten each 15 mm nut to 33 lbs-ft. (Fig. 5-7) Fig. 5-7 (s) Route the pig tail wire harness from each lamp directly rearward and through the grill. (Fig. 5-8) (t) Connect the pig tail connector to the mating connectors on the wire harness and secure the with 2 wire ties as per step 4f. Fig. 5-8 Issue: C 06/03/08 Page 12 of 15 pages DIO